Warp knitted pile fabric having each pile end bound entirely in one wale



July 5, 1960 R. s. MacCAFFRAY, JR 2,943,470

WARP KNITTED PILE FABRIC HAVING EACH PILE END BOUND ENTIRELY IN ONE WALE Original Filed Nov. 8, 1957 9 Sheets-Sheet 1 y 1960 R. s. M CAFFRAY, JR 2,943,470

WARP KNITTED PILE FABRIC HAVING EACH PILEI END BOUND ENTIRELY IN ONE WALE Original Filed Nov. 8, 1957 9 Sheets-Sheet 2 6/ j 5 6/ INVENTOR fax 61 MMWWJ? 2,943,470 G EACH FILE END BOUND ENTIRELY IN ONE WALE Original Filed Nov. 8, 1957 R. S. M CAFFRAY, JR WARP KNITTED FILE FABRIC HAVIN .Fuly 5, 196% 9 Sheets-Sheet 3 ATTORNEY.

INVEN OR Rex e5 Maa'a/ZIQi/W y 1960 R. s. MacCAFFRAY, JR 2,943,4?0

' WARP KNITTED FILE FABRIC HAVING EACH PILE END BOUND ENTIRELY IN ONE WALE Original Filed Nov. 8, 1957 9 Sheets-Sheet 4 July 5, 1960 R. s. MacCAFFRAY, JR 2,943,470

WARP KNITTED FILE FABRIC HAVING EACH PILE END BOUND EINTIRELY IN ONE WALE Original Filed Nov. 8, 1957 9 S eets-Sheet 5 July 5, 1960 R. s. MaccAFFRAY, JR 2,943,470

WARP KNITTED FILE FABRIC HAVING EACH FILE} END BOUND ENTIRELY IN ONE WALE Original Filed Nov. 8, 1957 9 Sheets-Sheet 6 INVENTOR y 1960 R. s. M CCAFFRAY, JR 2,943,470

WARP KNITTED PILE FABRIC HAVING EACH PILE END BOUND ENTIRE-LY IN ONE WALE Original Filed Nov. 8, 1957 9 Sheets-Sheet 7 INVENTOR 7 Rex J 4/4: fiafl r'ay, W.

mew m qmmz 2% Q25 New KZEQ July 5, 1960 R. s. M cAFFRAY, JR 2,943,470

WARP KNITTED PILE FABRIC HAVING EACH- PILE END BOUND ENTIRELY IN ONE WALE Original Filed Nov. 8, 1957 9 Sheets-Sheet 9 W 1 r D-PIELE FABRIC HAVING EACH FEE END BQUND ENTKRELYINQNE WALE Rex S. Mac'Cafiray, .lr., BoilingSprings, Pa, assignor to t). H. Masland and Sons, Carlisle, Pa, a corporation ofPennsylvania 2 Claims. (Cl. 66-191) The present invention relates to warp knitted pile'fabrics, such as carpets and rugs.

The present application is a division. ofimy'copending application Serial No. 695,325,. filed. November 8,. 1957, for Machine and Method For Making Warp Knitted Pile Fabric Having Each Pile End Entirely In One wale.

A purpose of the invention is to provide a warp knitted pile fabric in which the consumption of pileyarn is reduced to a minimum, avoiding lay-in of. face yarn from chain to chain or course to course.

A further purpose is to accomplish the hind of each pile yarn end entirely from a single knitted chainuand to carry each pile yarn end immediately up into a pile projection again after it is bound without any intermediate lay-in stretch.

A further purpose is to alternately project pile projections from a knitted chain on opposite sides, and preferably to provide mutual support between opposed pile projections, projecting opposite adjoining pile projections in the same course.

A further purpose is to form the pile of pilewarp ends in warp knitting by shogging alternately in opposite directions to form loops within the same wale, and preferably oppositely to the shogging of a guide. bar for another frame of face yarn.

Further purposes appear in the specification. and in the claims.

In the drawings I have chosen to illustrate a few only of the numerous embodiments. in which my invention may appear, selecting the forms shown from the standpoints of convenience in illustration, satisfactory operation and clear demonstration of the principles involved.

Figures 1 to 8 are diagrammatic stepwise vertical sectional views illustrating the positions of the operating parts at different stages of the knitting cycle.

Figure 1 corresponds to the position of zero or 360 degrees of the cam; Figure 2 corresponds to the position of 30 degrees; Figure 3 is for 90 degrees; Figure 4 is for 150 degrees; Figure 5 is for 210 degrees; Figure 6 is for 270 degrees; Figure 7 is for 300 degrees and Figure 8 is for 330 degrees.

Figures 1a to 8a respectively are diagrammatic enlarged plan views showing the formation of the knitted fabric according to Figures 1 to 8. These views show several knitted chains, but illustrate only one backing yarn end, with fragments of others, and illustrate two frames of pile yarn ends, with one end of each frame shown, and omitting the others.

Figure 9 is a diagrammatic fragmentary top plan view of a fabric of Figures 1 to 8 and la to 8a.

Figure 10 is an enlarged fragmentary coursewise sec tion on the line ltl-dtl'of Figure 9.

Figure 11 is a cam diagram showing the operation of the main elements of knitting.

Figure 12 is a diagrammatic perspective of a knitting machine in accordance with the invention.

Figure 13 is a diagrammatic end elevation of the guide 2,43,4'20 Patented July 5,1960" 2 bar operating mechanism employed in the knitting machine of 'the invention.

Figure 14 is a diagrammatic end elevation. of the plush point operating mechanism of the invention.

Figure 15 is a diagrammatic end elevation of the needle bar operating mechanism of the invention.

Figure 16 is a view similar to Figure 7, but illustrating acutting plush point.

Figure 17 is a view similar to Figure 9, showing a two frame warp knitted pile fabric of the invention with an end ofeach pile frame in each wale, omitting the laid-in back.

Figure-18 is anenlarged section on theline 1818 of Figure 17.

Figure 19 is a fragmentary plan view of a cut pile fabric according to the invention, omitting the backing and showing only a single pile frame.

Describing in illustration: but not in limitation andreferringto the drawings:

In the prior art practice of warp knitting of pile fabrics, the. usual procedure has been to form a loop or tuft and bind it in a knitting chain, and to shog to carry the pile yarn end to another wale, in the same or a succeeding course to complete the loop between the wales and to bind in such loop by the knitted chain in such other wale. This method of knitting, while pro.- ductive of a satisfactory pile formation, does not provide for economical utilization of pile yarn.

I have discovered that by modifying the manipulation of the pile warp ends, I can greatly improve the coverage or economical utilization of pile yarn and at the same time gain definite structural advantages.

In the fabric of the present invention, unlike that of the prior art, mutual lateral support is obtained between pile projections, and pile projections are in effect associated in opposite acting couples or pairs, which are urged against one another.

Accordingly, for a given yarn composition and pile height, a much more resilient pile is obtained which has less tendency to pack or felt and which resists matting;

In accordance with one of the aspects of the invention, whether I employ a single frame or pile yarn guide bar, or multiple frames or pile yarn guide bars, the pile yarn ends are always shogged or manipulated in each course opposite to the loop forming manipulation of the preceding course, but they are fastened in the same wale indefinitely'so that if the structure could be imagined brought into a. single plane in plan, the pile yarn ends (prior to cutting where they are cut) are of serpentine formation bound in the stitchesv of a single chain at the opposite sides of each loop.

Where a single frame of pile yarn is to bev used, it will preferably be cut.

Where two or more'frames of pile yarn ends are employed, whether of the same color or of different colors, very desirable fabrics can be obtained whether cut or uncut. in this case it is preferable to shog each pile yarn guide bar in a particular course opposite to the other pile yarn guide bar, so that the loops of the two frames are opposed to one another and mutually support. This can be accomplished by an alternate threadin, in which there are ends-in of pile frame A in the even numbered tubes and ends-out or seeded in the odd numbered tubes, and ends-out or seeded of pile frame B in the even numbered tubes and ends-in at the odd numbered tubes. This can also be accomplished using a complete thread-in of both frames, each having an end-in in each one of the pile yarn guide bar tubes.

Considering first the form of Figures 1 to 8 and 1a to So, which shows the operation using noncutting plush points, in a fabric which is either entirely uncut or cut and uncut, but shown at the position of a noncutting plush point, it will be evident that Figure 1 illustrates the condition at zero or 360 degrees.

A stationary vertically extending trick plate 40, as well known in the art in knitting machines of this character, is generally of tapered cross section, having a side 41 extending generally vertically and supporting the fabric being formed and removed by suitable take-off mechanism, and a side 42 suitably slightly converging and adjoining the needles. The trick plate at the top has a suitable needle guiding portion 43 and a fiat top 44 beneath the level of the sinkers. The warp knitting loom employed is of the double needle bar type, one needle bar mounting supports 45 for a series of latch needles 46 of well known type which extend vertically and are guided by the trick plate. The latch needles as shown in Figure 1 have hooked ends 47 at the top directed away from the trick plate and latches 48 pivoted at 50 and in one position closing against the hook ends.

The other needle bar in the device of the invention, at the opposite side of the trick plate, is equipped with plush points 51 instead of needles, mounted on supports 52 in the illustration of Figures 1' to 8. The plush points are for producing uncut loops and take the form of metal lic strips having hook portions 53 on the side toward the needles, blunt upper ends 54 and fillets 55 at the ends on the sides remote from the needles.

Immediately above the trick plate and adapted to move across it, there is a sinker comb 56 mounted on a sinker support 57.

Suitably positioned above the sinker and extending horizontally clear across the machine is a swing bar which carries positioned thereon a horizontally slidable guide bar 58 which carries tubes or eyes 60 for knitting yarn 61; then next behind there is a horizontally slidable guide bar 62 which carries tubes or eyes 63 for guiding pile yarn 64; then next behind is horizontally slidable guide bar 65 which carries tubes or eyes 66 for guiding a second frame of pile yarn 67; then next behind is a horizontally slidable guide bar 68 which carries tubes or eyes 70 for guiding backing yarn 71. A latch wire 72 extends across the back of the machine as well known.

Considering first Figures 1 and la, corresponding to zero dgerees or 360 degrees on the earns, the first step of the new cycle is being taken after completion of the last stitch. The needles 46 and the plush points 51 are down or retracted, the sinker comb 56 is advanced or forward, and the swing bar with the guide bars on it is in midposition and moving back.

If desired, shagging of the pile yarn and backing yarn will take place at the position of Figure 1. It is decidedly preferable to shog pile yarn at this position, although the shogging of backing yarn at this position is entirely optional.

As shown in Figure 1a, the thread-in is an alternate staggered thread-in in this form, there being an end of pile yarn frame A in each alternate trick or wale, and an end of pile yarn frame A omitted or seeded in the alternate tricks or wales. The thread-in of pile yarn frame B is just the reverse, since it has its ends-in in the tricks where pile frame A has its ends omitted or seeded. In many cases the pile yarn ends of the different frames will be of different colors.

Thus the previously formed loops 73- of Figure la are made from ends of pile yarn 67 on guide bar 65, while the previously formed loops 74 in the adjoining tricks on either side are made from pile yarn ends 64 on pile yarn guide bar 62 of the opposite pile frame. These loops are bound in by stitches 75 of chains 76 which also grip bundles 77 of backing yarn 71.

Figure 2 corresponds to 30 degrees of advance of the cycle. The position of the needles and of the sinkers is the same as that of Figure l. The guide bars are now all the way at the back, out of line with the plush points, and

the plush points 51 have just completed their forward or upward motion.

Figure 2a shows the position of the yarn ends, which is that of Figure 1a except for the guide bar position.

Figures 3 and 3a correspond to the position of 90 degrees in the cycle. The swing bar, and the guide bars for the knitting yarn and the pile yarn have moved to the front, and, as shown in Figure 3a, the pile yarn guide bars 62 and 65 each shog in opposite directions to carry pile yarn 64 and 6-7 respectively in opposed new loops 78 and 86 around the plush points.

Figures 4 and 4a show the position at 15 0 degrees in the cycle. The swing bar has moved back, carrying with it the guide bars, while the positions of all of the other knitting elements remain the same. The pile yarn guide bars 62 and 65 now continue to shog in the directions in which they had shogged at the position of Figure 3, to complete the formation of the loops 78 and 80, wrapping the pile yarn around the front of the plush points. Backing yarn 71 also shogs to form the lay-in or weft of the backing at this point.

The position of Figures 6 and 6:: corresponds to 270 degrees in the cycle. All shogging except that of the knitting yarn has been completed at Figures 4 and 4a. In Figures 5 and 5a, the face yarn and the knitting yarn guide bars have moved forward past the plush points. The needles have advanced or raised and the latches have been opened by the previous knitted stitch 81, while the previous knitted stitch has moved down on the needles below the latches, leaving the hooks of the needles open and the latches down.

The position of Figures 6 and 6a corresponds to 270 degrees in the cycle. All guide bars have moved to the back of the plush points and needles, and the new stitch is ready to be formed as shown by loops 82 (Figure 6a) of knitting yarn surrounding the bundles of backing yarn and surrounding the new pile loops 78 and to bind the pile loops. The knitting yarn guide bar is now shogged to place the knitting yarn around the needles beneath the hooks and above the latches.

Figures 7 and 7a at 300 degrees show the guide bars moving to the front and midway in their swing. The sinker comb 56, which has been in position across the fell and across the end of the trick plate above the plush points, is now retracting to clear the ends of the needles and the needles are beginning to retract, causing the latch to be closed by the previous stitch. The plush points in this form retract, either ahead of the needles, behind the needles or with the needles as desired.

Figures 7 and 7a also show the condition just before casting off, the pile loops being raised around plush points behind the plane of the drawing of Figure 7.

Figure 8 corresponds to 330 degrees and shows the stitch completed and locked. The sinker comb is fully retracted and is now about to advance again to the position of zero or 360 degrees as shown in Figure 1. Figure 8a shows the new loops 78 and 80 completed and cast oif.

Figures 9 and 10 show knitted pile fabric produced by the technique of the invention.

It will be noted that in each trick the pile loops oppositely project from and are bound into the same chain, to form what might be described as right hand loops 83 and left hand loops 84. Since there is always a right hand loop 83 from one chain which i abutting against a left hand loop 84 from the next chain, as best seen in Figure 10, since the guide bars of the pile frames are always shogging oppositely, it will be evident that mutually supporting or leaning engagement occurs at 85, which assures that the pile projections will tend to remain upright, will be resistant to flattening, and will be of superior resilience.

This condition exists throughout the fabric, where the loops are arranged in pairs, each with an opposite counterpart supporting loop at one side.

It.will also be evident that=the bind of thechain 76 is at the front of the fabric, and each pile loop, after it is bound, immediately rises again in a new loop, without any requirement for lay-in, so thatan extremely. economical and eflicient utilization is made of the ,pile yarn. Even where for other purposes it is desired to employ lay-in of pile yarn, it will be evident that/the principle of the invention can be used inparticular areas to obtain efficient utilization of pile yarn-in between lay-in.

The operation of knitting in accordance with Figures 1 to is illustrated by the cam diagram of Figure 11, which shows in the ordinate the angular position throughout a complete cycle.

The left column indicates swing bar position between the point side and the needle side. The next column shows needle position up or down. The next column shows plush point position up or down and the last column at the right shows sinker comb position in or out.

Figure 12 illustrates the warp knitting machine diagrammatically and Figures 13, 14 and 15 show actual cam mechanism.

The warp knitting machineof the invention maybe as described in D. F. Paling, Warp Knitting Technology (1952), Chapter 11, Raschel Warp Looms, and Chapter 12, Raschel Warp Loom Mechanism, with slight modifications as described herein.

The machine of Figure 12 has a frame 86 which jour nals a suitably horizontal front shaft 87 having a hand wheel 88 and carrying plush point drive cams 90, one of which is best seen in Figure 14, which has a cam track 91 receiving a: cam-follower 92, which pivotally connects to the free end of a lever 93, having a fixed pivot on the frame at 94. The pivotal connection of the follower 92 also pivotally connects to one'endof a link 95, which atthe far end has a pin 96'Which adjustably pivot-allyconnects in an arcuate-slot 97 on-plush point arm 98, which is keyed on a plush point bar shaft 100 extending horizontally across and. journaled in the frame. The plush point cam conformsto thecam layout of Figure. 1.1.. 'l he plush point arms 98 carry plush point bar 101 which carries the plush point support 52 and this holds the plush points 51.

The needle operating mechanism at the back of the machine is identical to that described for the plush points. A rear drive shaft 102 extends horizontally across the machine and is journaled in the frame, mounting needle bar cams 103, one of which is shown in Figure 15, having a cam track 104 which receives a cam follower 105 pivotally connected at one end of a lever 106 having fixed pivotal mounting 107 on the frame. The cam follower 105 also pivotally connects to the end of the link 108 which at the other end has a pin 110 adjustably pivotally connected in an arcuate slot 111 in the outer end of needle arm 112 which is keyed on needle bar shaft 113 extending across the machine and journaled in the frame. Needle bar 114 is supported on the needle arms and carries needle mounting 45 which positions needles 46. The layout of the needle cam is shown in Figure 11.

Above the plush points and the needles, swing bar shaft 115 extends horizontally across the machine, is journaled in the frame and carries the swing bar 116 as best seen in Figure 13. The guide bars already described in connection with Figures 1 to 8 are positioned in horizontally slidable mountings with respect to the swing bar 116. The guide bars are shogged by the pattern control mechanism of the kind shown in Paling above, beginning at page 145.

The swing bar has secured thereto at one end swing bar arm 117 having arcuate adjustment slot 118 which receives an adjustment stud 120, which pivotally connects to one end of adjustable link 121, which at the other end has a cam follower 122 which engages in cam track 123 of swing bar cam 124 operating on shaft 102. A link 125 pivotally connects to the follower 122 at one end and at the other end is loosely supported around front shaft 87.

6 The front shaft is suitably driven by the. rear shaft by gear .126 keyed ontherear shaft and interconnecting through pinions 127 and 128 with a gear 130'ke'yed on the front shaft.

The pile yarn for the machine comes from a suitable creel throughtubes 131 (Figure 12) and each yarn en'd suitably passes under one r'olle'r 132 and over one roller 133 of a particular; pair of cooperating feed rollers. Knitting yarn is supplied by a suitable constant feed mechanism 134 (Figure 12) and backing yarn is' supplied by suitable constant feed mechanism 135. p

While of course various pattern chain link combinations can be used, the'following is an example of a preferred pattern chain link sequence in accordance with the present invention:

. Knitting Plle Pile Backing Stitches Ghain' Yarn A Yarn B Yarn Guide Guide Guide Guide Bar Bar Bar" Bar l-1-l 0' 0-1-1-1 3-2-1-1 2-2-04] I 0-0-0-1 1-0-0-0 0-1 22 Y 22-"4-'-4 In some cases it will be preferred to make a cut fabric or a cut and uncut fabric, in which case at the point where the pile loops are to be cut, a plush point 51 (Figure 16) has a wedge knife 136 on the side remote from the needle, sloping progressively away from the needle in the direction from the top toward the bottom. The plush point has-at th'eupper end a fiatt'op 137 and at the side toward the needle has a hook end 138,v as best described in my coperrding application Serial No. 666,312, filed June 18, 19-57,Jfor Cutting Plush Point for Carpet Knitting. This hook end prevents the lay-in hacking yarn from going in front' ofthe plush point during the cycles of the swing bar. There is also at the upper end remote from the needle a hook'end 141 which prevents casting'otf when the push point is retracted.

As willzbe seen in Figure 16, theheel of the plushpoint at 141 is shaped so that it isgenerally parallel to the near side of the trick plate and engages the fabric, exerting a holding function as explained in my application above referred to.

The operations performed where cutting plush points are used are similar to those described in connection with Figures 1 to 8 for noncutting plush points, except that Figure 16 (corresponding to Figure 7) illustrates that one or more loops 142 remain around the cutting plush point when it retracts, and when the cutting plush point rises on the next cycle a previous loop which is tightly engaging the knife by pulling down along the blade as the take-up of the fabric progresses, is cut, forming cut pile tufts 143 as shown.

In some cases, using multiple frames, instead of intermediate thread-in, as previously described, I prefer to use a complete thread-in of an end of pile frame A and of pile frame B in each trick. An uncut pile of this character is shown in Figures 17 and 18, Where the pile ends of frame A form one zigzag 144 at each chain and the opposite frame B forms an opposite zigzag 145 at each chain, so that each stitch binds two loops projecting in opposite directions from the same knitting chain. In this case, therefore, there are opposed mutually adjoining pairs of pile projections 146 and 147 in each trick or wale of each course, whereas in the fabric of Figure 9 these mutually supporting loops occur only in each alternate trick or wale of each course. The result is that the fabric of Figures 17 and 18 is much denser than that of Figures 9 and 10, and tends to give still better pile support and assures greater resilience and greater resistance against flattening.

The principles of the invention as explained in con nection with Figures 9 and 10, and 17 and 18 apply also with any desired thread-in of the character previously discussed where cut pile is used rather than uncut pile,

as shown in Figure 19. Here each of the knitting chains 76 binds a U-shaped pile yarn element 148 which is bound at the middle at 150 in the stitch and forms two projecting tufts 151 and 152 which are upstanding .in the pile. It will be evident that when viewed in coursewise section there is a tendency of these same tufts to mutually support one another in pairs. The tufts have been drawn in noninterfering position in Figure 19 for convenience in illustration, but in fact they laterally support one another. 1

Figure 20 illustrates the face of warp knitted pile fabric of the invention conforming to Figure 9. It will be evident that the loops in this fabric are arranged in mutually supporting pairs.

It will be evident that in accordance with the presen invention, relatively inexpensive fabrics can be produced which nevertheless have high appeal since all of the pile yarn is effectively used in the face of the fabric, and burying of pile in the back of the fabric is avoided.

It will be evident that alternate pile projections tend to be slightly shadowedby the other pile projections of the pile and this lends'itself particularly to creating a moresque effect even where the pile yarn of frame A and frame B, although of different solid colors, is alternately slightly masked. This is very desirable to break up lining and row effects and to conceal defects in knitting. The moresque effect is due to the fact that the face yarn bar running with the knitting chain tends to be dominant over the face yarn bar running opposite to the knitting chain in any course, because the yarn on this bar running with the knitting chain travels a longer path in the'knitting operation.

It will be evident, of course, that where it is desired to avoid the dominance of one pile frame over another this can be avoided by'regulating the tension of the pile yarn frame that would otherwise be dominant, to increase the tension on this pile yarn on that cycle, using equipment as described in my copending application Serial No. 689,113, filed October 9, 1957, for Knitted Pile Fabric Having High and Low Pile In The Same Course.

In view ofmy invention and disclosure variations and modifications to meet individual whim or particular need will doubtless become evident to others skilled in the art, to obtain all or part of the benefits of my invention without copying the fabric. shown, and I, therefore, claim all such insofar as they fall within the reasonable spirit and scope of my claims.

Havingthus described my invention what I claim as new and desire to secure by Letters Patent is:

1. A warp knitted pile fabric comprising walewise extending parallel chains of knitted stitches, in-laid backing weft yarn ends extending walewise but each undu-t lating sinuously across and bound into the stitches of at least three of the knitted chains, and pile warp ends extending Walewise, each undulating sinuously across and anchored in successive stitches of only one of the said knitted chains so -as to form pile loops projecting out wardlyv front the fabric and leaningalternately rightwardly and leftwardly from its anchoring chain, the pile loopsanchored in successive chains along any particular course leaning alternately rightwardly and leftwardly from their anchoring chainsinto mutual supporting engagement so that each rightwardly leaning .loop receives support from a leftwardly leaning loop and vice versa.

2. A pile fabric of claim 1, in which at the same wale .and course anchored in the same chain there are both leftwardly and rightwardly leaning loops.

References Cited in the file of this patent UNITED STATES PATENTS 1,475,325 Springthorpe Nov. 27, 1923 2,213,720 Seim Sept. 3, 1940 2,396,525 Newman Mar. 12, 1946 2,435,897 Newman Feb. 10, 1948 2,476,153 Little et a1. July 12, 1949 2,531,718 Rice Nov. 28, 1950 2,718,132 Herrnstadt Sept. 20, 1955 

